Method of manufacturing magnetic iron and steel



Patented Dec. 31, 1 935 METHOD OF MANUFACTURING MAGNETIC IRON AND S' IEEL Heihachi Kamura, Tobata-Shi, Japan No Drawing. Application August 18, 1934, Serial N0. 740,433. In Japan September 24, 1933 9 Claims.

This invention is a modification of the invention for which a co-pending patent application Serial No. 679,869 was filed on July 11, 1933, and relates to improvements in magnetic iron and steel. I

An object of this invention is to provide magnetic material .having superior magnetic properties adapted'for use in electrical apparatus, in place of usual silicon steel.

Another object of this invention is to provide magnetic iron and steel having higher electric resistance and malleability than those of the aforesaid co-pending patent application.

Another object of this invention is to provide a method of manufacturing magnetic material having superior magnetic properties adapted for use in electrical apparatus, in place of usual silicon steel on industrial scale.

Other objects and particularities of this invention will be made clear by the following descriptions.

In order to manufacture my carbonless phosphorus-steel alloy, carbonless reduced iron manuufactured by the hydrogen reducing process, electrolytic iron or other extrem ely-low-carbon iron is mixed in suitable proportion with high-phosphorus reduced iron produced by the hydrogenreducing process from high-phosphorus iron ore or iron ore with phosphorus or with low carbon term-phosphorus, and a small percentage of,

silicon or titanium in the form of carbonless metallic silicon or titanium, or of carbonless silicon-steel or titanium-steel added thereto; the mixture is melted in a high-frequency induction furnace, melting pot, or the like, at a temperatube of 1,600 to 1,700 C.; and impurities in the charge are removed therefrom. By this process substantially carbonless iron can be obtained. The first and the second materials are mixed to gether in suitable proportions and my carbonless steel alloy having suitable silicon or titanium content will be obtained. As to the hydrogen reducing process, reference is made to my paper in The Transactions of the Electrochemical Society, vol. LXII, 1932, pp. 283-296.

Contrary to the presence of carbon in iron and steel, I have found that phosphorus in carbonless iron and steel materially increases the magnetic permeability of the metal, while it decreases the retentivity thereof and consequently the hysteresis? energy loss therein, and I have found that a small percentage of silicon or titanium included therein does not damage the superior magnetic properties but makes mechanical treatment easy for any desirable shaping and increases the electrical resistance required for some sorts of electrical apparatus. For this purpose, silicon lower than 2.5% and titanium lower than 1.0% is desirable.

My carbonless phosphorus-steel alloy containing 0.3 to 0.5 per-cent of phosphorus, 0.01 to 2.5% of silicon and from a trace to 1.0% of titanium has permeability of 9,000 to 12,000 gausses/sq. cm. and hysteresis loss of 1,300 to 1,600 ergs/cu. cm./cycle, and the alloy containing 0.5 to 1.0 per cent of phosphorus, 0.01 to 2.5% of silicon and 0 to 1.0% of titanium has permeability of 12,000

. to 15,000 gausses/sq. cm. and hysteresis loss of 1,200 to 1,400 ergs/cu. cm/cycle. It is, therefore, obvious that my alloy has a permeability almost twice that of commercial silicon steel, while the hysteresis loss in my alloy is nearly one half of that in commercial silicon steel. My alloy has also a suflicient malleability for pressing, rolling and other mechanical treatment. The above data show that my carbonless phosphorus-steel alloy is suitable for magnetic material in dynamo electric machines and other electrical and magnetic apparatus.

The cost of manufacturing my high-phosphorus carbonless steel alloy is less than yens per ton of ingot in view of several practical manufacturing data, and far cheaper than that of I silicon steel.

Magnetic iron and steel according to this invention have a slightly lower maximum permeabilitythan those of the aforesaid co-pending patent application, and a slightly higher hysteresis loss than the latter, but have materially higher electrical resistance and malleability for mechanical treatment than the latter.

I claim as my invention:-- a

1. Method of manufacturing magnetic iron and steel, comprising mixing carbonless reduced iron with high-phosphorus reduced iron produced by hydrogen reducing process using iron ore containing high phosphorus, adding thereto a small percentage of silicon, and melting the same.

2. Method of manufacturing magnetic iron and steel, comprising mixing electrolytic iron with high-phosphorus reduced iron produced by hydrogen reducing process using iron ore containing high phosphorus, adding thereto a small percentage of silicon, and melting the same.

3. Method. of manufacturing magnetic iron and steel, comprising mixing carbonless reduced iron with high-phosphorus reduced iron produced by hydrogen reducing process using a mixture of iron ore and phosphorus ore, adding thereto a small percentage of silicon, and melting the same.

4. Method of manufacturing magnetic iron and steel, comprising mixing electrolytic iron with high-phosphorus reduced iron produced by hydrogen reducing process using a mixture of iron ore and phosphorus ore, adding thereto a small percentage of silicon, and melting the same.

5. Method of manufacturing magnetic iron and steel, comprising mixing carbonless reduced iron with high-phosphorus reduced iron produced by hydrogen reducing process using iron ore containing high phosphorus, adding thereto a small percentage of silicon and titanium, and melting the same. I

6. Method of manufacturing magnetic iron and steel, comprising mixing electrolytic iron with high-phosphorus reduced iron produced by hydrogen reducing process using iron ore containing high phosphorus, adding thereto a small percentage of silicon and titanium, and melting the same.

'7. Method of manufacturing magnetic iron and steel, comprising mixing carbonless reduced iron with high-phosphorus reduced iron produced by hydrogen reducing process using a mixture of iron ore and phosphorus ore, adding thereto a small percentage of silicon and titanium, and melting the same.

8. Method of manufacturing magnetic iron 5 and steel, comprising mixing electrolytic iron with high-phosphorus reduced iron produced by hydrogen reducing process using a mixture of iron ore and phosphorus ore, adding thereto a small percentage of silicon and titanium, and melting the same.

9. The herein described method of manufacturing magnetic iron and steel containing from a trace to 0.03% of carbon, 0.3 to 2.0% of phosphorus, 0.01 to 2.5% of silicon, from a trace to 1.0% of titanium and up to 0.04% of manganese 'wholly or substantially free of impurities, which method comprises mixing together iron having an extremely low carbon content, high-phosphorus reduced iron produced by hydrogen reducing process and -a substance selected from the class consisting of carbonless metallic silicon, titanium, silicon steel and titanium steel and melting the mixture.

, HEIHACHI KAMURA. 

